Land Rover Defender Workshop 1993 Rover Manual

							GENERAL SPECIFICATION DATA 
TRANSMISSION 
Main gearbox 
Type 
- Manual LT77 5-speed helical  constant mesh, with 
synchromesh  on all forward gears 
0.795:1 
Fifth (Cruising gear) 
Fourth  1.000:1 
Third  1.436:1 
Second  2.180:1 
First  3.650:1 
Reverse  3.718:1 
............................................................. Main gearbox ratios 
Transfer  gearbox 
Type ........................................................................\
............. LT230T. Two-speed reduction  on main gearbox 
output.  Front and rear  drive permanently  engaged via 
a  lockable differential. 
Overall ratio 
........................................................................\
.. In high In  low 
transfer  transfer 
Fifth (Cruising  gear)  3.9663:1  9.3401:1 
Fourth  4.9893:1  11.7471:1 
Third  7.1656:1  16.8712:1 
Second  10.8786:1 
25.6134:1 
First  18.2094:1 
42.3734:1 
Reverse  18.9497:1  44.9233:1 
Rear Axle - One Ten only 
Type ........................................................................\
............. Salisbury  8HA 
Ratio  ........................................................................\
............  3.538:1 
Track  ........................................................................\
............  1485,90  mm 
Rear Axle - Ninety only 
Type ........................................................................\
............. Land Rover  spiral bevel 
Ratio 
........................................................................\
............. 3.538:1 
Track 
........................................................................\
............ 1485,90 mm 
Front Axle 
Type ........................................................................\
..................................... Land  Rover  spiral bevel 
Ratio 
.................................................. 3.538:1 
Track 
........................................................................\
............ 1485,90  mm 
PROPELLER SHAFTS 
Type:  Front  and rear ....................................................... Single  Hookes  universal needle  roller joints. 
SUSPENSION 
Type ........................................................................\
............. Coil springs  controlled  by telescopic  dampers front 
Front  ........................................................................\
..........  Transverse location of axle  by Panhard  rod. and fore 
Rear  ........................................................................\
.............  Fore and aft movement  inhibited by two  trailing links 
and 
rear 
and  aft location  by two  radius  arms 
Lateral location  of axle  by a centrally  positioned  A 
bracket  bolted at the  apex  to a ball  joint mounting. 
Defender  110 has a levelling unit  is positioned 
between  the ball joint and upper  cross member 
3 REVISED: OCT 1993  
						

							GENERAL SPECIFICATION  DATA 
BRAKES 
System ........................................................................\
......... Direct acting servo assisted dual  braking system with 
Girting tandem  master cylinder  and G valve 
Foot brake 
Front 
Type 
........................................................................\
.. Lockheed  Disc 
Number 
of pistons  per wheel ................................... 4 
Total lining  area 
...................................... 
Disc Diameter....................................................... 300 mm 
Lining  material .................................................................. 
Type ..................................................................... Lockheed DISC 
Disc diameter ................................................................ 290 mm 
Number 
of pistons  per wheel ........................................ 2 
Lining  material  ..................................................  Don  230  (Asbestos) or Ferodo  3440 
Type 
........................................................................\
...... Girting  single cylinder  drum brake 
Drum diameter 
.............................................................. 280 mm 
Total lining  area 
............................................................ 493 cm² 
Brake  drum width 
.......................................................... 63.9 mm 
Lining material 
.............................................................. Ferodo 2629 
(Asbestos)  or Ferodo 3440 (Asbestos  free) 
Rear 
disc brakes 
Rear  drum  brakes 
Handbrake 
Type 
........................................................................\
... Transmission  drum  brake  cable operated 
Drum  diameter 
..................................................................... 254 mm 
Lining  material 
...................................................................... Don 269 
STEERING 
Power steering box 
Make/type ........................................................................\
.... Adwest Varamatic - worm and roller  box 
Ratio 
.............................................................:..........\
............. Variable:  straight ahead 19.3:1 on  lock 17.2:1 
Steering  wheel turns, lock-to-lock ................................... 3.75 
Steering pump 
Make/type ........................................................................\
.... Hoboum-Eaton series 200 
Full lock  (left or right)  at idle .............................,................... 28 kgf/cm² (400 p.s.i.)  minimum 
Full  lock (left 
or right) 1000 rev/min ...................................... 70-77 kgf/cm²  (1000-1100  p.s.i.) 
Steering  geometry 
Toe
-out measurement ........................................................ 0 to 2.0 mm 
Toe
-out included  angle ..................................................... 0° to  0° 16 Camber angle .................................................................. 0°  Check with vehicle  in static 
Castor  angle ...................................................................  3° 
Swivel  pin inclination  static 
........................................... 7° 
Steering damper .................................................................. Double acting fitted between drag  link and  pinion 
Steering  column 
type ............................................... 
Operating  pressure - straight  ahead position  - at  idle .......... 7 kgf/cm²  (100 p.s.i.)  maximum 
Steering 
wheel diameter ...................................................... 420mm  unladen condition. that is. 
vehicle  with water. 
oil  and  five gallons  of fuel 
Rock  the vehicle up  and 
down  at the  front  to allow 
it  to  take  up a static 
position 
housing 
Collapsible coupling 
4 REVISED: OCT 1993  
						

							GENERAL SPECIFICATlON DATA 
ELECTRICAL EQUIPMENT 
System ........................................................................\
.................... 
Battery 
Type:  12 
volt,  negative  ground 
Lucas - standard  9 plate ............................................... B.B.M.S.  No.371 
Chloride 
- standard  9 plate ........................................... B.B.M.S. No.2911 
Lucas - cold  climate  13 plate 
Chloride 
- cold  climate  13 plate .................................... B.B.M.S.  No.3693  Designation 
90/84/90 
B.B.M.S.  No.389  Designation 
15/120/92 
Alternator 
Type ........................................................................\
............. Magnetti  Marelli A127-85 
Rotor 
- winding  resistance ................................................... 2.6 ohms  at 2O°C  ± 5% 
New  brush  length 
................................................................. 20 mm 
Renew  brush at 
.................................................................... 10 mm 
Brush  spring  pressure 
.......................................................... 1.3 - 2.7  N 
Regulator  controlled  voltage 
................................................ 13.6 - 14.4  volts  measured  across battery 
Starter  motor 
Brush spring  tension ............................................................ 1020 gms 
Brush  minimum  length 
......................................................... 9,5 mm 
Distributor & MFI  system .................................................. See ‘ENGINE  TUNING DATA 
Wiper motor 
Armature end-float ............................................................... 0,1 - 0,20 mm 
Minimum  brush length 
.......................................................... 4,8 mm 
Fuses 
Type ........................................................................\
............. Cartridge  fuses, located in a box below  the facia 
Maximum 
D.C. output 
at 6000  rev/min ................................ 85 amps 
Stator 
- winding  resistance  per phase .................................. 0.092  ohms at 20°C  ± 5% 
Type 
........................................................................\
............. Magnetti  Marelli M78R pre-engaged 
Type 
........................................................................\
............. Lucas 14W uprated  two-speed 
panel,  which protect  the electrical  components. 
A  complete  list of circuits  protected  is given  in 
Electrical  Section. 
A  second  fuse box located  in the  engine  compartment 
next  to the  brake  servo  contains  fuses to protect  the 
vehicle  harness.  For fuse  values  refer to the  Electrical 
Section. 
REVISED: OCT 1993 5  
						

							GENERAL SPECIFICATION DATA 
Coil 
Make/type ........................................................ 
Distributor 
Make/type 
........................................................................\
.... Lucas 35 DLM8 
Application 
........................................................................\
... 12V Negative  ground 
Pick
-up  air gap  adjustment 
Bosch 0221 122 392 
Firing  angles  ................................................................. 
0°-45°-90° (every 45°) ± 1° 
(Pick-up Iimb/reluctor  tooth) 
................................................. 0.20 mm to 0.35 mm 
Pick-up  winding resistance 
.................................................. 2k to 5k ohms 
Horns  Make/type 
........................................................................\
.... Klamix (Mixo) TR99 
Ignition 
module 
Spark  plugs 
Make/type 
........................................................................\
.... Champion  RN9YC 
REPLACEMENT  BULBS AND UNITS 
Headlamps ........................................................................\
... 60/55 W halogen  sealed beam 
Front  side lamps 
.................................................................. 12V 5W 
Side marker lamps ............................................................... 12V 3W 
High  mounted stop light ....................................................... 12V/5W 
Flasher lamps ...................................................................... 12V 21W 
Reverse  lamp ....................................................................... \
12V 21W 
Interior lamp ........................................................................\
. 12V 21 W 
Warning  lights ...................................................................... 12V 1.2W 
Instrument illumination ......................................................... 12V 2W 
Hazard  switch warning  light ................................................. 12V 1.2W (red) 
Heated  rear Screen  switch  illumination 
................................ 12V 1.2W (green) 
Heated  front screen  switch 
illumination ............................... 12V 1.2W (green) 
Heated  front  Screen  warning light 
........................................ 12V 1.2W (amber) 
Cigar  light illumination 
.......................................................... 12V 1.2W 
Make/type ........................................................................\
.... Lucas  9EM amplifier  module, distributor  mounted 
Stop/tail  lamps 
..................................................................... 12V 21/5W 
Number  plate lamp ............................................................... 12V 4W 
6 RE-ISSUED:  FEB 1993  
						

							GENERAL SPECIFICATION DATA 
VEHICLE DIMENSIONS 110 
Overall length ............................................................... 
Overall width ........................................................................\
 1790mm 
.................................................................. 2035mm 
Wheelbase 
........................................................................\
.. 2794mm 
Track:  front and rear 
............................................................ 1485,90mm 
Ground  clearance:  under differential 
.................................... 215mm 
Rear opening  height (interior) .............................................. 1205mm 
VEHICLE DIMENSIONS 90 
Overall  length ....................................................................... \
4072mm 
Overall  width 
........................................................................\
 1790mm 
Overall  height 
....................................................................... \
2035mm 
Wheelbase 
........................................................................\
... 2360mm 
Track:  front and rear 
............................................................ 1485,90mm 
Ground  clearance:  under differential 
.................................... 229mm 
Tailgate  aperture  width 
........................................................ 864mm 
Tailgate  height 
..................................................................... 1300mm 
Interior  width 
........................................................................\
 1450mm 
Width  between  wheelboxes 
................................................. 925mm 
VEHICLE  WEIGHTS  AND PAYLOAD 
When  loading  a vehicle  to its  maximum  (Gross Vehicle  Weight),  consideration  must be taken of the vehicle 
kerb  weight  and the distribution 
of the payload  to ensure  that axle  loadings  do not  exceed  the permitted 
maximum  values. It 
is the customers  responsibility to limit the vehicles  payload in an  appropriate  manner such 
that  neither  maximum  axle loads  nor 
Gross Vehicle  Weight are exceeded. 
NOTE: 
CURB WEIGHT 
equals the minimum  unladen vehicle weight plus full fuel  tank. 
GROSS VEHICLE  WEIGHT equals the maximum  all up  weight,  with the driver,  passengers. 
payload  equipment  and towing  attachment  load (where  applicable) 
GROSS VEHICLE  WEIGHT CONDITION - the maximum axle weights  shown are individual axle 
loadings  which allow for the  fitting 
of optional  equipment.  The loading  of both axles up to their 
respective  maximums MUST  BE AVOIDED, as the  overall  maximum  vehicle weight would then 
be  exceeded. 
REVISED:  OCT 1993 7  
						

							GENERAL SPECIFICATION DATA 
WHEELS AND TIRES 
DEFENDER 
90 
Wheels 
Alloy 
Tires  Steel 
7.0 X 16 
7J X 16 X 33 
Type  and size 
BF Goodrich  LJ265/R16  Mud Terrain Radial Ply 
DEFENDER 110 
Wheels 
Steel  139,70mm 
x 406,40mm 
Tires 
Type and size  750X  12,8m (tubed) 
USE RADIAL PLY TIRES ONLY 
TIRE PRESSURES 
WARNING:  Tire pressures  must be checked with the tires  cold,  as the  pressure  is about  0,21 bar  higher 
at  running  temperature. 
If the vehicle  has been  parked In the sun or high  ambient  temperatures,  Do not 
reduce  the tire  pressures,  move the  vehicle  into the shade  and wait  for the tires 
to cool  before  checking 
the  pressures. 
General  Notes 
Emergency  soft pressures  should only be used in extreme  conditions  where extra  flotation is required 
Max speed 40 km/h (25 mph).  Return  pressures to normal  immediately firm ground  is regained. 
Towing  When vehicle  is 
used for towing the reduced  rear tire pressures  for extra  ride  comfort  are not 
applicable 
WARNING: Do  not replace the  road  wheels  with any type  other  than  genuine Land Rover  wheels, as 
they are designed for multi-purpose  on and off road  use and  have very  important  relationships with  the 
proper  operation 
of the  suspension  system and vehicle  handling.  Replacement  tires should be of the 
size  recommended 
in this manual  and all be the  same  make,  ply  rating  and  tread pattern. If in any 
doubt, 
consult Land Rover Service  department for advice. 
8 REVISED: OCT 1993  
						

							ENGINE TUNING DATA 
ENGINE 3.9 V8 
Type ........................................................................\
............. 3.9 Litre  V8 
Firing  order ........................................................................\
. 1-8-4-3-6-5-7-2 
Cylinder  Numbers 
Left bank ........................................................................\
...... 1-3-5-7 
Right  bank 
........................................................................\
.... 2-4-6-8 
No 1 Cylinder  location ....................................................... Pulley end of left bank 
Timing  marks ...................................................................... On crankshaft vibration  damper 
Spark plugs 
Gap ........................................................................\
.............. 0.84-0.96mm 
Coil 
Make/type ........................................................................\
.... Bosch 0-221-122-392, (ETC  6574) 
Compression  ratio ............................................................. 9.35:1 
Fuel injection  system ........................................................ Lucas 14 CUX Hot-wire air flow sensor  system 
electronically controlled 
Valve  Timing  Inlet Exhaust 
Opens ........................................................................\
.......... 32° BTDC 
Closes 
........................................................................\
.......... 73°  ABDC 
Duration 
........................................................................\
....... 285°  285° 
Valve  peak  104°  ATDC  114° BTDC 
Idle speed - controlled  by MFI system ............................. 700 ± 25 rev/min 
Base  idle speed .................................................................. See  setting procedure - 525 ± 25 rev/min. 
Ignition  Timing - dynamic  at idle  speed, 
vacuum  disconnected 
....................................................... 5° BTDC  ± 1 ° 
Exhaust  gas 
CO content at  idle ................................................................ 0% to 0.05% max.  70° 
BBDC 
35°  ATDC 
........................................................................\
... 
REISSUED: FEB 1993 1  
						

							TORQUE WRENCH SETTINGS 
ENGINE Nm 
Alternator mounting bracket to cylinder head ...................... 40 
Alternator to mounting bracket ............................................. 24 
Chainwheel to camshaft ....................................................... 58 
Cylinder head: 
Centre  row 
........................................................................\
... 92 
Distributor  clamp nut ............................................................ 21 
Fan to viscous unit ............................................................... 30 
Flywheel to crankshaft ......................................................... 78 
Inlet manifold to cylinder  heads ........................................... 51 
Lifting eye to cylinder heads ................................................ 24 
Main bearing  cap rear  bolts ................................................. 92 
Manifold  gasket clamp  bolt .................................................. 17 
Oil plug ........................................................................\
......... 28 
Oil relief valve cap ................................................................ 40 
Alternator to adjusting  link .................................................... 24 
Connecting rod bolt .............................................................. 51 
Outer row ........................................................................\
..... 58 
Inner row ........................................................................\
...... 92 
Exhaust  manifold to cylinder heads ..................................... 21 
Main bearing cap  bolts ......................................................... 72 
Oil pump cover to timing  cover ............................................ 13 
Oil sump  drain plug .............................................................. 45 
Oil sump to cylinder block .................................................... 10 
Oil sump  rear to cylinder  block ............................................. 18 
Rocker  cover to cylinder  head ............................................. 7 
Rocker shaft  bracket to cylinder head .................................. 37 
Spark plug ........................................................................\
.... 15 
Starter  motor attachment ..................................................... 44 
Damper to crankshaft ........................................................... 271 
Timing  cover to cylinder block .............................................. 27 
Viscous  unit to water pump  hub ........................................... 45 
Water  pump  pulley to water  pump  hub ................................ 10 
Water  pump  timing cover to cylinder  block .......................... 27 
FUEL  LINES 
Connections  at straight  connector ....................................... 16 
Pipe connections at filter ...................................................... 16 
Hose  clips ........................................................................\
.... 2 
Connections  at vapour separator ......................................... 16 
Connections at  Tee-piece .................................................... 16 
CLUTCH 
Clutch  cover bolts ................................................................ 27 
Slave cylinder bolts .............................................................. 27 
REISSUED: FEB 1993 1  
						

							TORQUE WRENCH  SETTINGS 
MAIN GEARBOX  (FIVE-SPEED) LT77S Nm 
Oil pump  body to extension case ......................................... 9 
Clip to clutch  release  lever ...................................... 
Attachment  plate to gearcase .................................. 
Attachment plate to remote housing .................................... 9 
Extension case to gearcase ................................................. 25 
Pivot plate ........................................................................\
.... 25 
Remote  selector housing  to extension case ........................ 25 
Gear  lever housing to remote  housing ................................. 25 
Guide clutch release  sleeve ................................................. 25 
Slave cylinder to clutch  housing ........................................... 25 
Front cover to gearcase ....................................................... 25 
5th support  bracket .............................................................. 25 
Plunger  housing to remote housing ..................................... 25 
Blanking  plug extension  case .............................................. 9 
Gear lever retainer ............................................................... 9 
Yoke to selector  shaft .......................................................... 25 
Fixing gear lever  assembly  nut ............................................ 44 
Reverse pin to centre plate  nut ............................................ 25 
Clutch housing to gearbox bolt ............................................ 72 
Plug - detent spring .............................................................. 25 
Oil drain plug ........................................................................\
 51 
Oil filter  plug ........................................................................\
. 72 
Plug oil filler - remote  housing .............................................. 30 
Breather ........................................................................\
....... 9 
Oil level plug ........................................................................\
 30 
Blanking plug - reverse switch  hole ..................................... 24 
Fifth gear  layshaft  nut .......................................................... 217 
c 
2 REISSUED: FEB 1993  
						

							TORQUE WRENCH SETTINGS 
TRANSFER GEARBOX LT230T Nm 
Pinch bolt operating arm ...................................................... 9 
Gate plate to grommet  plate ................................................ 9 
Bearing housing to transfer case ......................................... 9 
Speedometer  cable retainer ................................................. 9 
Locating plate to gear  change .............................................. 6 
Bottom cover  to transfer ....................................................... 25 
Fixings  securing  mounting brackets to gearbox ................... 90 
Speedometer  housing 
.......................................................... See note 
Front  output  housing  to transfer 
........................................... 25 
Front  output  housing to transfer ........................................... 25 
Cross shaft housing  to front output housing ........................ 25 
Gear  change ........................................................................\
 25 
Gear change ........................................................................\
 25 
Cross shaft  to high/low  lever ................................................ 25 
Pivot shaft to link  arm ........................................................... 25 
Connecting  rod ..................................................................... 25 
Front output housing cover .................................................. 25 
Pivot bracket to extension  housing ...................................... 25 
Mainshaft bearing housing to transfer case ......................... 25 
Anti-rotation plate  intermediate shaft ................................... 25 
Finger housing to front  output housing ................................ 25 
Brake drum to coupling  flange ............................................. 25 
Gearbox  to transfer case ..................................................... 45 
End cover bearing housing  to transfer case ........................ 45 
Speedometer  housing to transfer ......................................... 45 
Selector finger to cross shaft (high/low) ............................... 25 
Selector  fork high/low to shaft ................................................... 25 
Transmission brake to speedometer  housing ................ 72 
Gearbox to transfer case ..................................................... 45 
Oil drain plug ........................................................................\
 30 
Detent  plug ........................................................................\
... Plug to be coated with  Hylomar and peened  Screw . 
Transfer case assembly ....................................................... See note 
plug  fully in (spring solid)  then turn two complete  turns 
back 
. 
Differential casings ............................................................... 60 
Front and rear  out flange ..................................................... 162 
Differential case  rear ............................................................ 72 
Oil filler and  level plug  transfer ............................................. 30 
Transfer breather ................................................................. 9 
Inner shaft stake  nut ............................................................ 135 
N0TE: Studs to be assembled into casings  with 
sufficient  torque to wind them 
fully home, but this 
torque must  not exceed the  maximum figure quoted 
for the associated  nut on final  assembly 
. 
FRONT  AXLE 
Hub driving  member to hub .................................................. 65 
Stub axle to swivel  pin housing ............................................ 65 
Upper swivel  pin to swivel  pin housing ................................ 65 
Lower  swivel  pin to swivel  pin  housing........................ 25 
Oil seal  retainer to swivel  pin housing ............................. 9 
Swivel bearing  housing  to axle case .................................... 72 
Pinion housing to axle case ................................................. 41 
Crown  wheel to differential  case .......................................... 58 
Differential  bearing cap  to pinion housing ............................ 90 
Universal  Joint flange to  propeller shaft 
............................... 47 
Mudshield to swivel pin housing .......................................... 9 
Bevel pinion nut 
................................................................... 129 
REISSUED: FEB 1993 3